1. Other Process Analysis/Modeling Tools
Flow Process Charts
Flow Diagrams
Assembly Charts
Activity Charts
Multi-Activity (Gang) Charts
Left-Hand Right-Hand Charts
Process Maps
Process: A sequence of events leading to some (intended) outcome.
For example
Manufacture (Freightliner) → finished trucks
Assemble dash harness → completed dash wiring harness
Fly aircraft → delivered passengers, cargo
Climb to assigned altitude → at desired altitude
Perform laparoscopic cholecystectomy → gall bladder removed
Insert Veress needle → needle in place
Purpose is to visually organize and structure a problem rather than to provide a solution.

2. Process Chart Symbols Operation Move Inspect Storage Delay
Operation + Inspection

3. Flow Process Chart (Single-Object Process Chart)
Source: Rago (1963)

4. Flow Process Chart (Detail)
Source: Rago (1963)

5. Flow Process Chart
Source: Groover, M., Work Systems. Upper Saddle River, NJ: Pearson Prentice Hall.

6. Flow Process Chart (Detail)

7. Flow Process Chart
Source: Gaither (1986)

8. Flow Process Chart (Detail)

9. Flow Diagram
Source: Groover (2007)

10. In-Class Exercise: (Flow) Process Chart, Flow Diagram
(handout)
Choose a simple activity you do frequently, e.g., Prepare microwave popcorn, Install ski rack on car
Do a flow process chart
Refer to text, Fig. 6.7 (p. 95)
Draw a flow diagram on the back
Refer to text, Fig. 6.8 (p. 95)
Hand it to the person in front of you to review, make suggestions to improve process
Additional copies of the process chart can be downloaded from the Resources section of the IE 366 home page.

11. Assembly Process Chart (Operation Chart)
Source: Groover (2007)

12. Assembly Process Chart
Source: Gaither (1986)

13. Assembly Process Chart (Details)
Source: Gaither (1986)

14. Activity Chart (one worker)
Source: Groover (2007)

15. Multi-Activity Chart (Gang Chart)
Source: Gaither (1986)

16. Multi-Activity Chart (Detail)

17. Left-Hand Right-Hand Chart
Source: Groover (2007)

18. Multi-Activity Chart (Worker-multimachine Activity Chart)
Source: Groover (2007)

19. Process Maps (Flow Charts)
Symbols
In spite of this, there does not seem to be standard formatting or symbology for process maps. The point is simply to map elements of a process to some graphical (typically flow chart) representation.

20. Process Map Source: Groover (2007)
Problems With Flow Process Charts, etc.
Reductionist: focus in on the details
“Lose the forest for the trees”
Lose the “big picture”
Focus on small problems/opportunities and miss the big ones.
(Assembly process charts can overcome these, to a certain extent.)
Source: Groover (2007)

21. Process Map Source: Overman (2007)
Problems With Flow Process Charts, etc.
Reductionist: focus in on the details
“Lose the forest for the trees”
Lose the “big picture”
Focus on small problems/opportunities and miss the big ones.
(Assembly process charts can overcome these, to a certain extent.)
Source: Overman (2007)

22. Casting Back-End Operations Process Map
Scrap?
Receive from
casting dept
Grind &
sandblast
Perform visual
inspection
Dispose
Yes No
Defects?
Rework
Yes No
Perform X-ray
inspection
Defects?
Yes No
Pack & ship